Torsion Spring Installation and Adjustment

We heartily thank the
Clopay
Company for allowing us to reprint this slightly modified instructional article on
installing torsion springs. Obviously, these instructions are designed
specifically for their own doors. But if you own another brand and
don't have access to the original instructions, you may find this information
useful as general information or as a general reference for adjustment and safety issues. NH

Please read and understand these instructions completely before proceeding
with the installation of torsion springs. Carefully follow these instructions to
avoid personal injury or property damage.

Important Safety Information

Torsion springs can be very dangerous if they are
improperly installed or mishandled. Do not attempt to install them yourself
unless 1) you have the right tools and reasonable mechanical aptitude or
experience and 2) you follow these Instructions very carefully.

Step 1 - Preparing the door frame

It is important that the torsion spring assembly be
firmly and securely attached to the frame of the garage.

Refer to Figure TOR-1 for the configuration of 2" x 6" wood jambs.

Important: The wood anchor pad must be made of a Grade 2 or better
southern yellow pine (also known as southern pine or yellow pine). Other
acceptable types of wood for this application are beech, birch, hickory, and
oak. The wood must be free of splits and cracks. Do not use wood labeled as
spruce pine fir (or SPF).

Each side jamb and the center anchor pad should extend 12" above the top of
the opening for 12" radius horizontal track and 15" above the top of the opening
for 15" radius horizontal track.

The wood anchor pad must be attached to the frame of the garage with at least
four 3/8" x 4" long lag screws for wooden frames or four 3/8" x 4" long sleeve
anchors for concrete frames. (one at each corner). The four fasteners must be
installed no closer than 1-1/2" from the sides and the ends of the anchor pad.
These fasteners must be embedded into the frame of the garage, not the drywall
or sheet rock. The wood anchor pad and fasteners are not supplied. Do not use
nails.

NOTE: The wood anchor pad can be off-center to the width of the opening by up
to 10" in either direction.

Step 2 - Assemble the torsion springs to the spring tube

Lock the door in the down position securely using
door lock or locking pliers. This must be done to prevent the door from
prematurely opening which could cause an injury.

NOTE: You need an assistant in Step 4. If your garage has only one entrance,
be sure you, the assistant, and the tools you need are inside before you lock
the door. Your door will have either one or two torsion springs. Each torsion
spring consists of spring coils, stationary cone, and a winding cone (FIG.
TOR-2). The spring coils are color-coded depending on the spring size and the
winding cone is color coded separately, either red or black. The color on the
winding cone is to help identify on which side of the door the spring is to be
used.

Black winding cone torsion springs are used on the right side of the door
and red winding cone torsion springs are used on the left side of the door when
viewing the door from the inside looking out. Failure to install the torsion
springs on the correct side will cause your door to function improperly and
could result in serious injury. (NOTE: If you have low headroom, these
instructions DO NOT APPLY. Consult supplemental low headroom instructions.)

Slip the torsion springs onto the spring tube, the red winding cone on
the left end, the nylon center bearing, center bearing plate, and the
black winding cone torsion spring on the right end (FIG. TOR-3).
Cable drums go on next, the red drum on the left, black drum on
the right. The set screws on the drums face the springs.

Step 3 - Attach mounting plates to garage door frame

Fasten the bottom of the end bearing plate to the horizontal angle with (2)
3/8" x 3/4" long hex head bolts and hex nuts. The bottom of the end bearing
plate is identified by two parallel rows of two slots. Please make sure to use
the bottom two slots for 12" radius horizontal track, and the upper two slots
for 15" radius horizontal track. When properly mounted the torsion tube is level
and straight (FIG. TOR-4A).

Before installing any lag screws, it is important to drill 3/16" pilot holes
where the lag screws are to be attached. Fasten the wall flange on the end
bearing plate to the wood jamb with (1) 5/16" x 1-5/8" long lag screw. Drill
3/16" pilot holes where lag screws are to be installed. On 12" radius horizontal
track, each end bearing plate should also be attached with 3/8" x 3/4" carriage
bolts and 3/8" nuts (FIG. TOR-4).

Step 4 - Attach assembled torsion springs to mounting plates

With an assistant, lift the complete torsion spring tube assembly and slide
the ends of the tube into the bearing on the end bearing plates. With the tube
level, mount the center bearing plate to the center anchor pad using (2) 5/16" x
1-5/8" long lag, red-coated screws.

NOTE: Red-headed fasteners must be installed for the attachment of
center bearing plate to indicate this part will be under extreme tension once
spring is wound (FIG. TOR-5).

Before mounting the center bearing plate, drill (2) 3/16" pilot holes for the
lag screws. These pilot holes must be no closer than 1-1/2" from the sides and
ends of the wood anchor pad. The center bearing plate resists the considerable
counter torque of the springs. This wood anchor pad must be installed to the
frame of the garage as stated in Step 1.

Step 5 - Install torsion spring cables

The cable that is attached to each bottom bracket is brought up between the
wall and roller shafts to the cable drum. This cable is placed in the notch on
the cable drum. Turning the cable drum and sliding it up tight against the end
bearing plate removes the cable slack. Make sure the cable follows the
grooves in the cable drum. The set screws on the cable drum should be
tightened with a 3/8" box wrench while holding the cable taut. Locking pliers
clamped to the torsion spring tube maintain tension on the cable (FIG. TOR-2).
This procedure should be repeated on the opposite side.

Step 6 - Adjust torsion spring with winding bars

Check for a straight line drawn across the length of the spring(s). If no
line is present, draw one using a piece of chalk. This will be used to indicate
the number of turns on the spring(s). After inserting the two winding bars all
the way into the winding cone, wind the springs 1/4 turn at a time in an upward
direction as shown in FIG. TOR-5. The number of turns is shown in the table in
FIG. TOR-2. The tail of the torsion spring coil points in the direction that the
spring is wound (FIG. TOR-5A).

NEVER use screwdrivers or other substitutes for
winding bars! Stand to the side of bars. Be sure to insert the bars all the way
into the hole.

Secure each spring with the set screws on the winding cone. (Caution:
Set screws should be turned from 3/4 to one full turn after they have made
contact with the tube.) On doors with two torsion springs, each torsion spring
should be wound the same number of turns. Remove the locking pliers.

Step 7 - Carefully test door function

Unlock the door, slowly raise the door and prop it about halfway open.

This is the first time the new door is being opened.
If the tracks are not correctly aligned or the back hangers are not strong
enough, the door may fall. Proceed slowly and carefully.

Check to be sure the horizontal tracks are parallel with each side of the
door. Make sure all the lag screws are securely fastened. With the door about
halfway open, make sure the rollers do not come out of the top brackets more
than about 1/2 inch. If adjustment of the rear track hanger is necessary, the
door must be locked in the closed position because the weight of the door is
supported by the rear hangers.

NOTE: If the torsion springs do not increase in tension as the 1/4
turns are added to the springs, then you probably have the torsion springs
reversed. (See Step 2.)

Step 8 - Final adjustments, if necessary

To adjust torsion spring tension, the door is locked in the down position.
With locking pliers clamped on the torsion tube, winding bars are used to wind
the springs tighter to increase tension. Tension is reduced by removing turns.
When two springs are used, both sides should be adjusted the same. Adjustments
should be made in 1/4 turn increments.

NEVER adjust center bearing plate or red-headed
fasteners after springs are wound. Be prepared to handle a strong force when
reducing tension on a torsion spring. Use winding bars only, and stand to the
side.